OISD - STD - 116FOR RESTRICTEDCIRCULATION ONLY

Amended Edition - October 2002

FIRE PROTECTION FACILITIES

FOR

PETROLEUM REFINERIES

AND

OIL/GAS PROCESSING PLANTS

OISD – STD - 116Amended Edition, October 2002

Oil Industry Safety DirectorateGovernment of India

Ministry of Petroleum & Natural GasDepartment of Petroleum & Natural Gas

OISD - STD - 116Amended Edition,

October, 2002

FOR RESTRICTEDCIRCULATION ONLY

FIRE PROTECTION FACILITIES

FOR

PETROLEUM REFINERIES

AND

OIL/GAS PROCESSING PLANTS

Prepared by

COMMITTEE ON FIRE PROTECTION

OIL INDUSTRY SAFETY DIRECTORATE7

thFloor, New Delhi House

27-Barakhamba RoadNew Delhi - 110001

II

NOTES

OISD (OIL INDUSTRY SAFETY DIRECTORATE) publications are prepared for use in the oil and gas industry under Ministry of Petroleum & Chemicals. These are the property of Ministry of Petroleum & Chemicals, Deptt. of Petroleum and Natural Gas and shall not be reproduced or copied and loaned or exhibited to others without written consent from OISD.

Though every effort has been made to assure the accuracy and reliability of the data contained in these documents, OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from their use.

These documents are intended only to supplement and not to replace the prevailing statutory requirements.

Note 1 in superscript indicates the changes / modifications / additions as approved in 20

thSafety Council Meeting held in October

2002.

III

FOREWORD

The oil industry in India is over 100 years old. Variety of practices have been in vogue because of collaboration / association with different foreign companies and governments. Standardisation in design philosophies & operating and maintenance practices at a national level was hardly in existence. This coupled with feedback from some serious accidents that occurred in the recent past in India and abroad, emphasised the need for the industry to review the existing state of art in designing, operating and maintaining oil and gas installations.

With this in view, Oil Industry Safety Directorate (OISD) was established in 1986 staffed from within theindustry for formulating and implementing a series of self regulatory measures aimed at removing obsolescence, standardising and upgrading the existing standards to ensure safer operations. OISD constituted a number of committees comprising of experts nominated from the industry to draw up standards and guidelines on various areas of concern.

The present document on 'Fire Protection Facilities for Petroleum Refineries & Oil/Gas processing plants' is First Revision of the document prepared by the Committee on 'Fire Protection' which was originally published in 1991. Attempts have been made to incorporate the latest technological changes, experience gained in its implementation during last 4-5 years and relevant changes in the light of various national and international codes and practices.

It is hoped that the provision of this document, if implemented objectively will go a long way in improving the safety in the oil & gas industry.

This document will be reviewed periodically for improvements based on the new experiences and better understanding. Suggestions from users/industry members may be addressed to :

The Co-ordinatorCommittee on 'Fire Protection'Oil Industry Safety Directorate

7th

Floor, New Delhi House27-Barakhamba Road

New Delhi 110001

IV

FUNCTIONAL COMMITTEE

ON

FIRE PROTECTION

LIST OF MEMBERS

Name Designation / Organisation StatusS/Shri

1. M.M.Kapoor

R.P. Bhatla(upto 31.12.94)

Engineers India Limited(w.e.f. 1.1.95)Engineers India Limited

Leader

Leader

2. A.A. Raichur Hindustan PetroleumCorporation Limited

Member

3. S. Neelkanthan Madras Refineries Limited

Member

4. P.J. Joshuva Cochin Refineries Limited

Member

5. Sunil Kumar Indian Oil CorporationLimited

Member

6. V.P. Vaidhya Hindustan PetroleumCorporation Limited

Member

7. S.N. Mukharjee Bharat PetroleumCorporation Limited

Member

8. A.K. Das Bongaigaon Refineries& Petrochemicals Ltd.

Member

9. R.P. Saxena Oil & Natural GasCorporation Ltd.

Member

10. H.K. B. Singh IBP Co. Ltd. Member11. Vijay M. Ranalkar Oil Industry Safety

DirectorateMemberCoordinator

In addition to the above, several other experts from industry contributed in the preparation, review and finalisation of the document.

5

FIRE PROTECTION FACILITIES FORPETROLEUM AND OIL/GAS PROCESSING PLANTS

CONTENTS

SECTION DESCRIPTION PAGENO.

1.0 Introduction2.0 Scope3.0 Definitions4.0 Fire Protection philosophy4.1 General considerations4.2 Design criteria5.0 Fire Water System5.1 Basis5.2 Flow Rate5.3 Header Pressure5.4 Storage5.5 Pumps5.6 Distribution Network5.7 Hydrants and Monitors5.8 Material Specifications5.9 Fixed Water Spray System5.10 Fixed Water Sprinkler System6.0 Foam Systems6.1 Types of Foam6.2 Low Expansion Foam6.3 Foam Conveying Systems6.4 Floating Roof Tank Protection6.5 Fixed Roof Tank Protection6.6 Floating cum Fixed Roof Tank Protection6.7 Dyke Area/Spill Fire Protection6.8 Foam Application Rate6.9 Duration of Foam Discharge6.10 Water for Foam Making6.11 Foam Quantity Requirement6.12 Foam Compound Storage7.0 Halon/Proven Equivalent Protection System7.1 Recommended Use7.2 Quantity and Storage7.3 Floating Roof Tank Protection

6

SECTION DESCRIPTION PAGE NO.

7.4 Control Room and Computer Room Protection8.0 Carbon Dioxide Systems8.1 Recommended Use8.2 System Design9.0 First Aid Fire Fighting Equipment10.0 Mobile Fire Fighting Equipment11.0 Storage of Fire Fighting Agents12.0 Detection and Alarm System Portable Fire Fighting Equipment12.1 Areas to be covered with Detectors13.0 Communication System14.0 Fire Protection System-Inspection and Testing14.1 Fire Water Pumps14.2 Fire Water Ring Main14.3 Fire Water Spray System14.4 Fixed Foam System14.5 Halon/its proven equivalent System14.6 Mobile Fire Fighting Equipment and Accessories14.7 Communication System14.8 Detectors15.0 Fire Fighting Organisation16.0 Fire Protection Training17.0 Mutual Aid18.0 Fire Emergency Procedures19.0 Fire Station/Control Room Mutual Aid19.1 Location19.2 Communication19.3 General20.0 Passive Fire Protection

References

A N N E X U R E SI Typical example for calculation of Fire Water Flow RateII Typical example for calculation of Foam Compound

RequirementIII Broad specifications for Fire Fighting EquipmentIV Fire Training Ground - FacilitiesV Typical Agreement of Mutual AidVI Fire Case in a large Floating Roof Tank after collapse of

floating roofVII Automatic Actuated Foam Flooding System for larger Floating

Roof TanksVIII Types of foam compound

7

FIRE PROTECTION FACILITIES FOR PETROLEUM REFINERIES

AND OIL/GAS PROCESSING PLANTS

1.0 INTRODUCTION

Even though petroleum refineries and oil/ gas processing installations are generally located in remote areas, experience shows that residential/industrial units come up in close proximity with the passage of time. Hence these installations which store large quantity of flammable materials, pose threat to surroundings as well, in addition to their own safety. Such conditions therefore, necessitates the introduction of in-built fire protection facilities.

It is impractical and prohibitively costly to design fire protection facilities to control catastrophic fires. Usual requirement of a good system is to prevent emergencies from developing into major threat to the installations and surroundings.

The requirement of fire fighting facilities, described in the following chapters shall be examined with due consideration to theavailability of the fire fighting services from city fire brigade and/or from other neighbouring industries.

2.0 SCOPE

i) This standard covers the design criteria and details of the various fire protection facilities to be provided in petroleum refineries and oil/gas processing plants.

ii) This standard also covers the LPG storage, handling and bottling plants located within the refineries and oil/ gas processing plants.

iii) This standard does not cover LPG storage, handling & bottling plants, Petroleum Depots, Terminals, Lube Blending plants & Pipeline Installations located outside the premises of Refineries and AFS, GGS, OCS & CTF which are covered in OISD-STD-144 on 'LPG Bottling Plant Operations' Q1SD-STD-169 on 'OISD Guidelines on Small LPG Bottling Plant' and OISD-STD-117 on 'Fire Protection Facilities for Petroleum

Depots and Terminals'.

However, in case of LPG storage, handling, bottling plants, Depots & Terminals, Pipeline Installations etc. located in close proximity of refineries and oil/gas processing plants under the same Management, this standard shall apply and common water storage, pumping facilities may be considered to protect the both.

3.0 DEFINITIONS

i) PETROLEUM REFINERY

'Petroleum Refinery" is a plant where crude oil is received and processed to produce various intermediates and finished products.

ii) OIL/GAS PROCESSING PLANT

'Oil/Gas Processing Plant' is a plant where oil/natural gas is collected and processed to produce Oil/LPG and other petroleum fractions. Drilling activities and facilities upstream of the Christmas tree of a well are not covered under this definition.

iii) LPG BOTTLING PLANT

'LPG Bottling Plant' is a plant where LPG is stored and filled into cylinders. Receipt and despatch of LPG by rail, road and pipeline are also considered under this definition.

iv) PETROLEUM DEPOTS, TERMI-NALSAND OIL INSTALLATIONS

'Petroleum Depots, Terminals and Oil Installations' are those locations where Petroleum crude/Products are received by tanker, pipelines, tank wagons and tank trucks and are stored or blended in bulk from where they are further despatched by tankers, pipelines, tank wagons, tank trucks, portable tanks or containers.

v) INSTALLATION

8

For the purpose of this Standard, installation includes all the facilities as listed in 3(i) to 3(iii) (located in a Refinery or Oil/Gas Processing Plant).

vi) Deleted

vii) CLASSIFICATION OF PETROLEUM PRODUCTS

a) General Classification of Petroleum Products:

Petroleum products are classified according to their closed cup FLASH POINTS as follows:

Class 'A' Petroleum: Liquids which have flash point below 23 degrees C.

Class 'B' petroleum: Liquids which have flash point of 23 degrees C and above but below 65 degrees C.

Class 'C' petroleum : Liquids which have flash point of 65 degrees C and above but below 93 degrees C.

Excluded Petroleum: Liquids which have flash point of 93 degrees C and above.

Liquefied gases including LPG, do not fall under this classification but form a separate category.

b) Classification for heated products :

At locations where the handling temperatures are higher than the flash point of the product in circumstances where product handled is artificially heated to above its flash point, class 'C' product shall be considered as Class 'B' product and Class 'B' product shall be considered as Class 'A' product.

viii) DELETED

ix) CLASSIFICATION OF FIRES

Class A Fires : Fires involving combustible materials of organic nature, such as wood, paper, rubber and many plastics, etc., where the cooling effect of water is essential for extinction of fires.

Class B Fires : Fires involving flammable liquids, petroleum products, or the like, where a blanketing effect is essential.

Class C Fires : Fires involving flammable gases under pressure including liquefied gases, where it is necessary to inhibit the burning gas at a fast rate with an inert gas, powder or vapourising liquid for extinguishment.

Class D Fires : Fires involving combustible materials such as magnesium, alluminium, zinc, sodium, potassium when the burning metals are reactive to water and water containing agents, and in certain cases carbon dioxide, halogenated hydrocarbons and ordinary dry powders. These fires require special media and technique to extinguish.

4.0 FIRE PROTECTION PHILOSOPHY

The Fire Protection Philosophy is based on Loss Prevention and Control. The importance of adequate fire protection facilities for hydrocarbon processing plants need not be emphasised as no plant is absolutely safe because of the inherent hazard it carries. A fire in one part/section of the plant can endanger other sections of plant as well. If fire breaks out, it must be controlled / extinguished as quickly as possible to minimise the loss to life and property and to prevent further spread of fire.

4.1 GENERAL CONSIDERATIONS

Special considerations shall be given to the size of process plant, pressure and temperature conditions, size of storage, plant location and terrain, as these determine the basic fire protection need. Layout of an installation shall be done in accordance with OISD-Standard-118 on Layouts. A good layout provides adequate fire fighting access, means of escape in case of fire and also segregation of facilities so that the adjacent facilities are not endangered during a fire.

The following fire protection facilities shall be provided depending upon the

9

nature of the installation and risk involved.

- Fire Water System- Foam System- Halon / its proven equivalent

System- Carbon Dioxide System- Dry Chemical Extinguishing

System- Detection and Alarm system- Communication System- Portable fire fighting equipment- Mobile fire fighting equipment

4.2 DESIGN CRITERIA

The following shall be the basic design criteria for a fire protection system.

i) Facilities should be designed on the basis that city fire water supply is not available close to the installation.

ii) Fire protection facilities shall be designed to fight two major fires simultaneously any where in the installation.

Fire water requirements will be decided as per guidelines given in Annexure-l.

iii) All the tank farms and other areas of installation where hydrocarbons are handled, shall be fully covered by hydrant System.

iv) Class 'A' petroleum storage in above ground tanks shall have fixed water spray system, whether floating roof or fixed roof.

v) Class 'B' petroleum storage tanks of following dimensions shall be provided with fixed water spray.

- Floating roof tanks of diameter larger than 30 mtrs.

- Fixed roof tanks of diameter larger than 20 mtrs

vi) a. Semi-fixed foam system shall be provided for the following tanks.Floating roof tanks storing Class 'A' and Class 'B' petroleum products.

- Fixed roof tanks storing Class 'A' and class 'B' petroleum products.

- Fixed roof tanks storing class 'C' petroleum products, of diameter larger than 40 mtrs.

b. Automatic Actuated Foam Flooding Proven System may be provided:

- on existing floating roof tanks where Semi-fixed foam system could not be provided.

- on floating roof tank larger than 60mtrs diameter( as an alternative to halon/its proven equivalent system)

vii) LPG Pressure storage vessels shall be provided with automatic water spray system.

viii) Water spray system shall be considered for hazardous locations and equipment in process unit areas. Some of these areas are:

- Uninsulated vessels containing class A or B flammable liquid having capacity larger than 50 m

3

- Vessels inaccessible to fire tender/ mobile equipment, fire hydrants

- Pumps handling petroleum products class 'A' under pipe racks

- Pumps handling products above auto-ignition temperature under pipe racks

- Air fin coolers located above pipe racks.

ix) Automatic water spray system shall be provided in LPG bottling stations, LPG loading/unloading gantries and LPG pump and compressor areas in all new refineries and for existing refineries this conversion to automatic shall be done in phased manner.

x) Water spray requirement with mode of operation to be considered in line with provisions under clause nos. 7.4.1 and 5.4.3 of OISD-STD-173. The water to be used should be clear and non saline.

Note 1